轮胎行业设备方案

轮胎行业设备方案2Copyright©2009RockwellAutomation,Inc.Allrightsreserved.21.轮胎生产过程中设备简述2.轮胎成型机应用介绍3.裁断机应用介绍3子午线轮胎断面结构图Copyright©2009RockwellAutomation,Inc.Allrightsreserved.34子午线轮胎断面结构图Copyright©2009RockwellAutomation,Inc.Allrightsreserved.45轮胎的生产过程Copyright©2009RockwellAutomation,Inc.Allrightsreserved.56工序一：密炼工序密炼工序把碳黑、天然/合成橡胶、油、添加剂、促进剂等原材料混合到一起，在密炼机里进行加工，生产出“胶料”的过程Copyright©2009RockwellAutomation,Inc.Allrightsreserved.67工序二：胶部件准备/工段三:胎圈成型Copyright©2009RockwellAutomation,Inc.Allrightsreserved.7原胎圈是由许多根钢丝挂胶以后缠绕而成的。用于胎圈的这种胶料是有特殊性能的，当硫化完以后，胶料和钢丝能够紧密的贴合到一起。相关设备:钢丝缠绕机8Copyright©2009RockwellAutomation,Inc.Allrightsreserved.8在这个工序里，帘布将被裁断成适用的宽度并接好接头。帘布的宽度和角度的变化主要取决于轮胎的规格以及轮胎结构设计的要求胶部件准备工序工序二：胶部件准备/工段四:帘布相关设备:

90度帘布裁断机9工序二：胶部件准备/工段五:三角胶贴合Copyright©2009RockwellAutomation,Inc.Allrightsreserved.9在这个工段里，挤出机挤出的三角胶条将被贴合到胎圈上。相关设备:三角胶贴合机10工序二：胶部件准备/工段六:带束层Copyright©2009RockwellAutomation,Inc.Allrightsreserved.10这个工序是生产带束层的。在锭子间里，许多根钢丝通过穿线板出来，再和胶料同时穿过口型板使钢丝两面挂胶。挂胶后带束层被裁断成规定的角度和宽度。宽度和角度大小取决于轮胎规格以及结构设计的要求。

所有的胶部件都将被运送到“轮胎成型”工序，备轮胎成型使用。相关主要设备:小角度度帘布裁断机11工序三：轮胎成型轮胎成型工序轮胎成型工序是把所有的半成品在成型机上组装成生胎，这里的生胎是指没经过硫化。生胎经过检查后，运送到硫化工序。Copyright©2009RockwellAutomation,Inc.Allrightsreserved.1112工序四：硫化硫化工序生胎被装到硫化机上，在模具里经过适当的时间以及适宜的条件，从而硫化成成品轮胎。硫化完的轮胎即具备了成品轮胎的外观—图案/字体以及胎面花纹。现在，轮胎将被送到最终检验区域了。Copyright©2009RockwellAutomation,Inc.Allrightsreserved.1213工序五/六：最终检验工序/轮胎测试

在这个区域里，轮胎首先要经过目视外观检查，然后是均匀性检测，均匀性检测是通过“均匀性实验机”来完成的。均匀性实验机主要测量径向力，侧向力，锥力以及波动情况的。均匀性检测完之后要做动平衡测试，动平衡测试是在“动平衡实验机”上完成的。最后轮胎要经过X-光检测，然后运送到成品库以备发货。在设计新的轮胎规格过程中，大量的轮胎测试就是必须的，这样才能确保轮胎性能达到政府以及配套厂的要求。

当轮胎被正式投入生产之后，我们仍将继续做轮胎测试来监控轮胎的质量，这些测试与放行新胎时所做的测试是相同的。用于测试轮胎的机器是“里程实验”，通常做的实验有高速实验和耐久实验Copyright©2009RockwellAutomation,Inc.Allrightsreserved.1314Copyright©2009RockwellAutomation,Inc.Allrightsreserved.142.轮胎成型机应用介绍Agenda15Copyright©2009RockwellAutomation,Inc.Allrightsreserved.15Agenda2.1成型机简介16DifferentTBMsfordifferentprocess&differenttypeoftire乘用/轻卡子午线轮胎全自动一次法成型机AutomaticUnistagePassenger/LightTruckRadialTBM乘用/轻卡子午线轮胎一段成型机1stStage&2ndStagePassenger/LightTruckRadialTBM两鼓全钢载重一次法成型机2-DrumsUnistageAll-steelRadialTruckTBM三鼓全钢载重一次法成型机3-DrumsUnistageAll-steelRadialTruckTBM三鼓子午线工程胎一次法成型机3-DrumsUnistageAll-steelRadialOTRTBM四鼓子午线工程胎一次法成型机4-DrumsUnistageAll-steelRadialOTRTBM巨型全钢工程子午线轮胎一次法成型机

AutomaticUnistageOTRTBM

...…轮胎制造过程的重要设备-成型机17Copyright©2009RockwellAutomation,Inc.Allrightsreserved.17成型机的性能要求HigherrequirementoncontrolsystemofTBM自动化程度高节省劳动力提高产品质量生产效率高控制各工序时间缩短停机再启动周期灵活性变更轮胎规格工艺调整精度直接影响轮胎质量18成型机的控制特点分析Copyright©2009RockwellAutomation,Inc.Allrightsreserved.18成型机的控制特点集合多种控制形式离散控制：繁复的逻辑和时序控制，包括工艺流程，各部件的时序动作及逻辑配合，数字量输出的控制(指示灯，气动原件，灯标步进电机，纠偏系统……)，模拟量控制:温度控制，压力控制，张力控制运动控制：多轴协动控制，对精度,速度,同步性均有要求。包括定长，电子齿轮，电子凸轮，插补等运动（旋转鼓，传送带，JLB排线，送料…….）传动控制：多台变频,变速控制（料卷导开，裁刀运动……..）安全控制：光幕，急停，拉线，地毯……网络技术的应用及对第三方设备的兼容人机界面，I/O，变频，灯标、阀岛、纠偏系统……I/O总数较多，站点分散，类型多DI，DO，AI，AO，SSI，IK……性价比要求高功能完善的人机界面报警，配方……19Copyright©2009RockwellAutomation,Inc.Allrightsreserved.19Agenda2.2成型机解决方案–RA集成架构20成型机解决方案–RA集成架构211.GUARDLOGIX集成安全控制器它具备ControlLogix控制器的全部功能，可实现顺序控制，传动控制，运动控制和过程控制的原有要求，并同时具有SIL3安全特性，这有助于确保安全控制。其双处理器架构（1oo2）和单一集成的软件开发，占有绝对优势。

2.安全分布式I/O在控制和监视复杂的安全系统回路的同时还具有传统分布式I/O的所有优点。安全I/O模块更易于在相同的接线上集成安全和标准控制。双通道模块支持模块用于Categroy4和SIL3应用。与GUARDLOGIX完美配合成型机解决方案–RA集成架构22RA全系列安全产品激光扫描器安全光幕安全地毯安全PLC急停&信号门开关非接触型开关密钥切换开关安全接触器安全继电器拉线开关安全变频器安全使能开关安全边缘23机械安全实例24轮胎成型机

25全自动一次法成型机安全地毯边缘开关激光扫描仪安全行程开关安全地毯安全行程开关26全自动一次法成型机安全光幕安全行程开关非接触式门开关拉线急停27成型机解决方案–RA集成架构3.带有GuardMOTION的KiNETIX®6000伺服驱动器安全停车功能在不切断整个系统供电的情况下完成。驱动器的输出可以禁止并消除电动机转矩，提供安全性和最大机器可用性。安全停车功能已通过TÜV认证，并符合EN-954-1Category3和IEC-61508SIL3关于安全停车和预防意外重启动应用的要求。28Objectbasedtagv.straditionalPLCaddressmappingObjectsconsistingof

IO,VFD,servodrive,instructionetc方案亮点29方案亮点OptionalmultipleprogramminglanguageLadderSFCSTFBD30Completeinstructionofmotion,drive,discrete,SIL3safetyetc34Motioninstructionsembedded方案亮点31Completeinstructionofmotion,drive,discrete,SIL3safetyetcESTOP EmergencyStop/急停DIN DualInput/双输入RIN RedundantInput/冗余输入ROUT RedundantOutput/冗余输出LC LightCurtain/光帘ENPEN EnablePendant/使能坠FPMS FivePositionModeSelector/五位选择开关方案亮点3200010203COMCOMT0T1M04050607COMCOMT2T3M00010203COMCOMCOM00010203COMCOMCOMCOMCOMFDBK2+FDBK2-FDBK1+FDBK1-SAFETYEN2+SAFETYEN-24V+24_COMSAFETYEN1+Safe-offConnectorKinetix6000DriveOSSD1OSSD224V+NCNC方案亮点33方案亮点34Copyright©2009RockwellAutomation,Inc.Allrightsreserved.34Agenda2.3.成型机典型控制环节35KeyApplication1:Cutting裁切IntermittentcuttingStage-1Axis1&2stopStage-2Axis1&2startatthesametimeandtrytorunatthesamelinespeedStage-2(VelocitySych.From0toV1)Step1:speedofAxis1&2increasefrom0toV1Step2:Axis1&2runatV1continuouslytillsensordetectthecuttingmaterialStage-3(PositioncontrolbaseonV1)AfterStage-2step2,Positionsych.(axis1&2)Whenreachthesettingposition,axesdeceleratetostopandwaitingfornextcycleRemarks:inthestage2,cuttingmaterialsometimesskidsonbelt(axis1),sointhisphaseweneedmakesureaxis1hasthesamevelocityasaxis2atanytime.36KeyApplication1:Cutting裁切功能块Master/SlaveLinearaxisHoming:Active/ImmediateThesensorshouldbeahigh-speedsensorandwiredintoMasterAxisDrivermoduleI/OportasRegistrationsignal.IncludeMSO/MAFRMDR(fornextPos.Registration)MRP(RedefinecurrentPos.=0)MAM1(ensuresensordetectedmaterial)MAM2:AbsolutePos.Movement(Registration_position+Fixed_distance)37KeyApplication2:Winding收卷total3typesmaterialswillbetransporttowindontheBigrollerEachmaterialwillbewindedontherolleronlyonecircleV2islinespeedontherollerAnytimeweneedmakesurethatV1=V2Duringwinding,thediameterofrollerwillbechangedMasteraxis=FeedingSlaveaxis=Winding38JLBWinding39MasterisWindingAxis;unitDegUnwindofMasteraxis=360Degree.SlaveisFeedingaxis;unitmmKeyApplication2:Winding

MasterisVirtualAxis;unitsencondSlaveiswindingaxis;unitmmMakesurethatthematerialswillbestretchedequablyateachpoint.40V1V2CalculatedataofFirstmaterialWindingParameter:D0(diameterofbigroller)D1(thicknessoffirstmaterial)D2(thicknessofSecondmaterial)D3(thicknessof3rdmaterial)StartWindsignalMastervelocityParameter:Lengthof3kindsofmaterialsbycustomerAftereachwind,thereisaangel.KeyApplication2:Winding41KeyApplication3:TransferRingPositionShapingDrumB&TDrumCarcassDrumCarcassRingB&TRingWaitingPositionCarcassPositionShapingPositionB&TDrumPositionWaitingPositionMAMMAJMAMMAJMAMMAJTorqueLimit42Copyright©2009RockwellAutomation,Inc.Allrightsreserved.42Agenda2.4.模块化编程43S88ProcessOrientedProgramStructure:

Unit,EquipmentModule,ControlModuleCM2CM1EM7CM2CM1EM6CM2CM1EM5CM2CM1EM4CM3CM2CM4CM1EM1CM1EM3CM2CM1EM2UNIT44TailSupportILConveyorCarcassDrumPLYConveyorStitcherLaserMarkTransferRingTireunloadShapingDrumStitcherTPConveyorTPDrumClampRingUNIT1CM4CM1EM1CM2CM1EM2CM3CM2CM1EM3CM2CM1EM4CM2CM1EM5CM2CM1EM6CM2CM1EM6S88ProcessOrientedProgramStructure:

TBMExle45S88ProcessOrientedProgramStructure:

TBMExleCM2CM1EM5CM2CM1EM4CM3CM2CM4CM1EM1CM1EM3CM2CM1EM2UNIT1UNIT1_BuildingStation1forAuto/SemiAuto/ManualStation2forAuto/SemiAuto/ManualInterlockingorhandshakingCommandSequencing1UNIT1_BuildingSequencing246TodeploypowerprogrammingforTBM

Step1:tounderstandmachineflowLevel1:UnitLevel2:StationFrontRackFirstStage_CarcassBuildingPLY(A)ConveyorILConveyorILLetOffPLY(N)ConveyorPLY(N)LetOffPLY(A)LetOffS-WallConveyorS-Wall(L)LetOffS-Wall(R)LetOffLevel3:EquipmentCarcassDrumNetherStitcherXStitcherYStitcherCarcassConveyorLevel4:ActuatorServomotorValveclutch47Level1:UNIT1_CarcassBuildingAutoLevel3:EquipmentModuleControlInterfaceCarcassDrumNetherStitcherXStitcher

YStitcher

CarcassConveyorLevel4:ControlModuleCM04AutoAxisCM10FResetCM21Enable

CM22Home

CM23Move

CM24Gear

CM27Jog

CM33Stop

CM35Disable

CM31StatusLevel2:StationModel&SequencingILConveyorS-Wall(R)LetOffResettingIdleRunningStoppedStoppingAbortingAbortedCarcass&ShapingDrumManualApplyPAApplyNPLYApplyAPLYBeadLoadShapingRemoveAutoControlSequenceManualControlCommandTodeploypowerprogrammingforTBM

Step2:totransferthemachineflowtoPPS01S02S10OperationModeEM10EM11EM13EM12EM14S01-Sq1S01-Sq2BladderUPStitchingSWApp48TodeploypowerprogrammingforTBM

Step3:toget1ststationdone(Confidential–ForInternalUseOnly)Copyright©2007RockwellAutomation,Inc.Allrightsreserved.48Level1WholeUnitOperationLevel3EquipmentModuleControlInterfaceLevel2StationModel&SequencingLevel4SingleActionExecuting49Level2StationModel&Sequencing

St